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TOC Reference Bank - Page 1
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Implementation Reference Bank

1.
P. L. Porter , United States.
Industry:  Automotive   Sales:  $25,000,000     
TOC Applications:  DBR  
Brief Summary:  WIP is down 800,000 dollars and profit margins are up. Did not have to spend millions of dollars changing entire MRP system
 Click here for details

2.
Grand Rapids Spring & Wire Products, Inc. , United States.
Industry:  Automotive   Sales:  $12,000,000     
TOC Applications:  DBR  
Brief Summary:  On-time deliveries have improved from a dismal 60% to 95%; inventories have decreased 30% while sales have doubled; cost of quality has dropped from 6% to less than 3.5%
 Click here for details

3.
Fluid Technology Corporation   Division:  Marlow Division , United States.
Industry:  Other   Sales:  $2,000,000     
TOC Applications:  DBR  
Brief Summary:  On-time delivery was at 75%, despite finished goods on 40 models and a lead time of 6 weeks on 29 others. On-time delivery is at 98% (most pumps beat the paperwork to the dock); shipments are up 30% since going to 2 day delivery; Finished goods has been eliminated and WIP is down 22%. Time to implement was approximately 8 weeks.
 Click here for details

4.
Ford Motor Company   Division:  Electronics Division , United States.
Industry:  Automotive   Sales:  $3,000,000,000     
TOC Applications:  DBR  
Brief Summary:  Used TOC to improve on major gains made with JIT between 1988 and 1991, reducing lead times by an additional 60-80% and improving on-time to 98%; eliminated need for two expensive plants saving approximately 100 million dollars; reduced quality defects by 50%; improved investment effciency by 20% and on-time delivery by 38%
 Click here for details

5.
Federal Mogul Corporation   Division:  Chassis Products Operation , United States.
Industry:  Automotive  
TOC Applications:  DBR ,TP applications  
Brief Summary:  TOC credited with saving the plant by helping achieve impressive turnaround - increased earnings 140%; throughput up 20%; operating expenses down 11% and production lead times down from 90 days to a range from 3 to 15 days.
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6.
Stanley Furniture , United States.
Industry:  Other  
TOC Applications:  DBR  
Brief Summary:  Lead times dropped from 10 weeks to 4 weeks, resulting in an inventory reduction of over 2 million dollars. Most orders are now shipped from production, not finished goods. Went from a shortage of buggies to hold material to an excess of 200 buggies.
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7.
Binney & Smith   Division:  Crayola Crayons , United States.
Industry:  Other  
TOC Applications:  DBR  
Brief Summary:  In less than a year, cycle times were reduced 70 to 80%; WIP inventory reduced over 80%, run sizes reduced 70 to 80% and setup reduced 30 to 60%
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8.
Monster Cable , United States.
Industry:  Other   Sales:  $20,000,000     
TOC Applications:  DBR ,TP applications  
Brief Summary:  Used to take 10 days from order receipt to shipping, today it is done in a few hours. TOC being applied to all areas -customer service, credit and sales force
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9.
Warren Featherbone Company , United States.
Industry:  Textiles & Apparel  
TOC Applications:  DBR ,Distribution  
Brief Summary:  Major improvements in entire supply chain - Warren Featherbone improved margins by nearly 20%, while improving turns from 2.5 to 4.5. Mercantile's retail store experienced gross margin increase of 135% and store space decreased 50%
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10.
Mercantile Stores , United States.
Industry:  Other   Sales:  $2,400,000,000     
TOC Applications:  Distribution ,TP applications  
Brief Summary:  Improvements in supply partners as well - creating win-win. Mercantile's retail store experienced gross margin increase of 135% and store space decreased 50%, while Warren Featherbone improved margins by nearly 20%, while improving turns from 2.5 to 4.5
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